CN111554443B - Processing technology of PEEK electromagnetic wire - Google Patents
Processing technology of PEEK electromagnetic wire Download PDFInfo
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- CN111554443B CN111554443B CN202010228659.8A CN202010228659A CN111554443B CN 111554443 B CN111554443 B CN 111554443B CN 202010228659 A CN202010228659 A CN 202010228659A CN 111554443 B CN111554443 B CN 111554443B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/065—Insulating conductors with lacquers or enamels
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
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Abstract
The invention belongs to the technical field of enameled wires, and particularly relates to a processing technology of a PEEK electromagnetic wire applied to a winding wire of a driving motor. The invention comprises the following steps: 1) preparing in the early stage; 2) preheating; 3) and paying off; 4) an extrusion coating step; 5) a cooling step; 6) and (5) taking up. The method has the advantages of fewer process control points, high step simplification degree, no need of additionally modifying the enamelling machine, great reduction in the emission of waste gas and waste liquid, and reduction in energy consumption; the PEEK enameled wire processed by the enameled wire production process provided by the invention has the advantages of high surface hardness, scratch resistance, chemical reagent resistance, high temperature and high pressure resistance and capability of adapting to various severe working environments, and can meet the production processing and use requirements of the existing manufacturers and customers on the PEEK enameled wire.
Description
Technical Field
The invention belongs to the technical field of enameled wires, and particularly relates to a processing technology of a PEEK electromagnetic wire applied to a winding wire of a driving motor.
Background
The requirements of a driving motor of a new energy electric vehicle on winding wires are higher and higher, such as high breakdown voltage, high PDIV, high temperature resistance, bending resistance and the like. In order to meet the use requirement of a driving motor, the thickness of a paint film (the double sides can reach more than 300 mu m) of the enameled wire must be increased. If the existing enameled wire processing technology is used for producing the ultra-thick paint film, the following defects exist: firstly, because the production mode of the enameled wire is multi-pass coating and repeated baking, in order to enable a paint film to reach the specified thickness, the original enamelling machine needs to be modified, and a plurality of machine heads are combined together for continuous production. The improved enamelling machine has the advantages that the capacity is reduced, the unit energy consumption of the product is increased, and simultaneously, the discharged waste gas is greatly increased. Secondly, the process is complicated, the product needs to be coated and baked for more than thirty times, the row line is too long, and part of the process parameters need to be adjusted: on one hand, the paint film is easy to be over-cured and damaged due to too many baking times in production, so that the product performance is influenced, and the eccentricity of the product is larger than that of a common product. On the other hand, the enameled wire passes through the guide wheel repeatedly in the production process, and the paint layer is damaged certainly, so that the quality of the product is reduced. Finally, the ultra-thick paint film is designed for meeting the purposes of high voltage resistance and high PDIV resistance of the driving motor coil, but the excessive thickness of the paint film can generate negative influence on other performances; the method includes, but is not limited to, the decrease of the flexibility of a paint film, the easy cracking of the paint film in the winding process of a driving motor coil, and the like, and can not meet the condition that some driving motors are used in severe working environments (such as high-temperature environments) for a long time, thereby bringing about a plurality of troubles to enameled wire manufacturers and users.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, and provides a processing technology of a PEEK electromagnetic wire which is reasonable in structure, reliable and convenient to use, less in process control points, high in step simplification degree, free of additional modification of an enamelling machine, greatly reduced in emission of waste gas and waste liquid and reduced in energy consumption; the PEEK enameled wire processed by the enameled wire production process provided by the invention has the advantages of high surface hardness, scratch resistance, chemical reagent resistance, high temperature and high pressure resistance and capability of adapting to various severe working environments, and can meet the production processing and use requirements of the existing manufacturers and customers on the PEEK enameled wire.
In order to achieve the purpose, the invention adopts the following technical scheme:
a processing technology of a PEEK electromagnetic wire comprises the following steps:
1) preparation in the early stage
Baking the PEEK particles at the temperature of 100-150 ℃ for more than 8 hours;
2) preheating step
Setting the temperature of each heating zone of the extruder, wherein each heating zone comprises a feeding zone, a preheating zone, an extrusion zone and a head part; the temperature of the feeding area is set to be 100-150 ℃; the temperature of the preheating zone is set to be 600-680 ℃; the extrusion zone is divided into three heating zones and the temperature increases in sequence along the extrusion direction: the temperature of the first zone is 280-300 ℃; the temperature of the second zone is 330-360 ℃; the temperature of the three zones is 360-400 ℃, and the temperature of the head part is consistent with that of the three zones in the extrusion zone; after the heating areas are heated in place and the temperature is kept for 30 minutes, the temperature in the feeding machine is ensured to be not lower than 100 ℃, then the feeding is carried out, and the extrusion operation is started;
3) and a step of paying off
After the die orifice of the extruder discharges materials, observing the trend of the die orifice materials, and adjusting the eccentricity of the core wire;
4) extrusion coating step
The machine head and the die orifice of the extruder are heated in a direct contact way through a heating sheet, and the temperature is measured through a hot spot coupling; stopping heating once the temperature exceeds the set temperature, and starting heating when the temperature is lower than the set temperature so as to keep the temperature within the set temperature interval;
5) step of Cooling
When the environmental temperature is below the specified temperature, directly cooling the PEEK enameled wire by air after the PEEK enameled wire comes out of the die; when the environmental temperature is higher than or equal to the designated temperature, cooling treatment is carried out by adopting an air cooling and/or water cooling mode;
6) and (5) taking up.
In the step 2), the core wire for feeding is prepared by the following steps:
a. step of wire drawing
Enabling a copper rod with the diameter of 2.5mm to enter a wire drawing box through a wire releasing device, drawing for multiple times to reach the specification of a specified product, cleaning and drying residual water stains on a wire surface, and then annealing; during annealing, the temperature of the annealing furnace is 450-550 ℃; the annealing temperature in the furnace is heated by an electric heating tube, and the thermocouple monitors and controls the temperature in real time; protecting the copper rod by using water vapor in the annealing furnace, and cleaning the copper wire again after annealing;
b. step of painting
Coating and baking the copper wire treated in the step a for more than eighteen times until a paint film reaches the specified thickness to form the core wire; and then, the core wire is wound on a spool through a winding device, and a surface lubricant is not used on the surface of the core wire before winding.
And 2) in the step, the preheating area of the extruder is heated by adopting an electric heating tube, and the thermocouple monitors and controls the temperature in real time.
And in the step 3), after the eccentricity adjustment of the core wire is finished, the core wire is led out from the pay-off machine and sequentially passes through the front tension pulley, the preheating zone, the machine head, the cooling zone and the rear tension pulley to reach the wire coil of the take-up machine.
In the step 5), the air cooling mode is as follows: and cooling the PEEK enameled wire by an air cooling machine after the PEEK enameled wire is discharged out of the die orifice of the extruder.
In the step 5), the water cooling mode is as follows: the PEEK enameled wire is directly immersed in cooling water after being taken out of a die orifice of an extruder by 10 cm; the temperature of the cooling water can be controlled by the heater, so that the temperature reduction speed of the coating is controlled.
The total thickness of the insulation layer of the PEEK enameled wire obtained by the wire collection in the step 6) is more than 300 microns, wherein the thickness of the PEEK coating is 80-200 microns.
The invention has the beneficial effects that:
1) the processing flow of the invention mainly comprises painting → baking → extruding; the PEEK enameled wire manufactured by the invention has the same thickness of the paint layer as that of the ordinary enameled wire, and the thickened part is directly replaced by the PEEK coating, so the painting and baking processes can directly use the existing enameled wire production line and processing technology. The extrusion process is directly cooled and formed after one-time coating, and is simpler and has fewer process control points. Compared with the traditional process for processing the extra-thick enameled wire, the combined processing technology provided by the invention has the advantages that the total insulation layer thickness of the PEEK electromagnetic wire processed is the same, the processing process is simplified, the enameling machine is not required to be additionally modified, the emission of waste gas and waste liquid is greatly reduced, and the energy consumption can be effectively reduced. Under the condition that the total insulation thickness is the same, compared with an ultra-thick enameled wire, the PEEK electromagnetic wire processed by the composite process has the advantages of being large in surface hardness, resistant to scraping, resistant to chemical reagents, resistant to high temperature and high pressure, resistant to various severe working environments and the like, extremely agrees with the use environment of a winding wire in the existing new energy electric vehicle driving motor, and extremely high in applicability.
Drawings
Fig. 1 is a block diagram of a processing flow of a PEEK enameled wire.
Detailed Description
Before the description, PEEK is first explained as follows:
PEEK (polyetheretherketone) is a crystalline polymer in polyaryletherketone polymers, is the most excellent high-performance engineering plastic, and is selected as an outer coating material for the following reasons:
1) high and low temperature resistance, the continuous use temperature reaches 260 ℃, and the low temperature can resist 100 ℃ below zero.
2) The chemical property is very stable, and only sulfuric acid in various common solvents can dissolve and destroy the sulfuric acid.
3) Water, seawater, steam, low permeability, low hygroscopicity, and stable structure and performance even if placed under humid and hot conditions for a long time.
4) The high-fluidity polypropylene material has good fluidity in a molten state, and has excellent mechanical properties and dimensional stability after solidification, so that the high-fluidity polypropylene material can meet the requirements through one-step processing and forming by an extrusion process, and the processing difficulty and the cost of products are reduced.
5) The good electrical characteristics are kept in a wider frequency and temperature range, and the insulation requirement of the electromagnetic wire is completely met.
6) The method is non-toxic and pollution-free, waste materials generated in the processing process can be completely recycled, and the method is environment-friendly and clean while the cost is reduced.
Based on the above advantages, PEEK as the outer coating layer material of the present invention can satisfy the design requirements of the present invention. In actual processing, main raw materials of the PEEK round electromagnetic wire are an oxygen-free copper rod, 220-grade polyamide-imide insulating paint and pure PEEK resin particles; the main raw materials of the flat wire product are an oxygen-free copper rod, 240-grade polyimide insulating paint and pure PEEK resin. For ease of understanding, the specific construction and operation of the invention is further described herein with reference to FIG. 1:
the overall processing steps of the invention are shown in figure 1, and comprise the following two processes:
firstly, a core wire manufacturing process:
firstly, semi-finished copper rods with the diameter of 2.5mm enter a wire drawing box through a wire releasing device, the specified specification of a product is achieved after a plurality of wire drawing processes, and the number of wire drawing times is determined according to the specification of the copper rods. Because the surface of the thinned copper wire is stained with the drawing oil, copper powder and other stains, the surface of the wire-blowing line is cleaned to leave water stains, otherwise, the subsequent processing steps are seriously influenced. As the copper wire is extruded and stretched by the die during wire drawing, the hardness is improved, the toughness is reduced, the conductivity is increased, and the copper wire needs to be annealed to be softened. The copper wire is passed through an annealing furnace, and is annealed electrically, the length of the annealing furnace and the DV value determining the annealing temperature, generally between 450 ℃ and 550 ℃. The annealing temperature in the furnace is heated by an electric heating tube, and the thermocouple real-time monitoring and temperature control are realized. Meanwhile, in order to prevent the copper rod from being oxidized by high temperature, the water vapor is used in the furnace to protect the copper rod. The copper wire also needs to be cleaned again after annealing to remove residual stains.
The annealed copper wire enters a painting step and is coated by a plurality of painting die layers and then baked. When the wire passes through one painting mold, the paint liquid is attached to the surface of the wire, and then the wire enters a large oven for baking. The large furnace is an electric heating furnace, the painted wire is subjected to solvent evaporation at high temperature, and the paint-based resin is crosslinked, cured and formed into a film. And the wire enters the painting mold again for secondary painting after coming out of the large furnace and then is baked again. And the paint film reaches the specified thickness after more than eighteen coating and baking. And then is taken up on a spool through a take-up device.
Note that no surface lubricant can be applied before the wire is taken up, otherwise the adhesion of the PEEK outer coating to the core wire surface in the next step is affected.
Secondly, PEEK enameled wire manufacturing process:
the invention adopts an extrusion process to carry out the subsequent PEEK external coating operation, the used production equipment is a common extrusion production line, and the processing flow is shown in figure 1.
1) Preparation in the early stage
Because processing PEEK needs to ensure that the material is pure and clean and cannot be wetted, otherwise, the processing process, the coating structure and the product performance are affected, PEEK particles need to be baked for more than 8 hours at the temperature of 100-150 ℃ before processing so as to ensure that moisture is completely removed. Important parts such as a die, a screw rod, a hearth, each heating unit, a cooling area and the like are cleaned and checked before starting up, so that production equipment and raw materials are prevented from being polluted.
2) Preheating step
The temperature of each heating zone of the extruder is set, and the heating zones comprise a feeding zone, a preheating zone, an extrusion zone and a head part. The temperature in the feeding machine is set to be 100-150 ℃, the temperature is kept consistent with or higher than the temperature of drying materials of the drying oven, residual moisture in the material cylinder can be thoroughly dried, and the PEEK material is prevented from being damped after entering the material cylinder. The preheating zone is used for dehumidifying the surface of the enameled wire and preheating the enameled wire, so that the part of the enameled wire entering the machine head is prevented from cracking and peeling due to sudden heating. The preheating zone is heated by adopting an electric heating tube in a heat radiation mode, the temperature is set to be 600-680 ℃, the wire diameter is larger, the temperature is set to be higher when the wire moving speed is higher, and the paint layer is excessively baked and aged due to overhigh temperature or overlow wire moving speed of the preheating zone. The extrusion zone is divided into three heating zones and the temperature increases in sequence along the extrusion direction: the temperature of the first zone is 280-300 ℃, the melting point of PEEK is 334 ℃, the temperature of the first zone is too high, so that the PEEK material is immediately melted and blocked and deposited after entering a hearth, and the melting effect of the subsequent PEEK material is influenced by too low temperature; the temperature of the second zone is 330-360 ℃, and the materials begin to melt; the temperature of the three zones is 360-400 ℃, complete melting of materials is guaranteed, and meanwhile the mobility of the PEEK melt in the temperature zone is good. The machine head part comprises a flange, a machine head and a die orifice, the temperature of the three heating zones is consistent with the temperature of the three zones in the extrusion zone, and the change of the temperature easily causes the change of melt flowability to influence the coating effect. And (4) waiting for the heating areas to be heated in place, carrying out heat preservation for 30 minutes, then loading, and starting the extrusion operation. The preheating zone uses thermal point coupling temperature measurement for feedback so as to control the temperature in the preheating zone to be constant. When the extrusion is started, the eccentricity of the die orifice is pre-adjusted, and secondary adjustment is performed after discharging.
3) And a step of paying off
After the die orifice discharges, the trend of the die orifice material is observed, the discharged material can deflect towards the direction with large eccentricity, the fastening screw in the direction is screwed, and the eccentricity is continuously and accurately adjusted. After adjustment is finished, the wire is led out from the pay-off machine and sequentially passes through the front tension pulley, the preheating zone, the machine head, the cooling zone and the rear tension pulley until the take-up machine receives a wire coil.
4) Extrusion coating step
The head and die are the most critical, and the temperature change directly affects the flow of the material, and further affects the coating effect, so the temperature of the discharging part must be ensured to be constant in the processing process. The machine head and the die opening are externally provided with heating sheets for direct contact heating, and hot spots are coupled for temperature measurement. And stopping heating once the temperature exceeds the set temperature, and starting heating when the temperature is lower than the set temperature so as to keep the temperature within the set temperature interval. The rotating speed of a main machine, namely the rotating speed of a screw and the traction speed, namely the traveling speed are adjusted according to the thickness of the PEEK coating required by the product, and the two parameters are not fixed; however, the preheating temperature is also increased while the drawing speed is increased, and the drawing speed is not too high or too low, so that the product line is excessively stretched when the drawing speed is too high, and the insulating paint layer is excessively baked when the drawing speed is too low. The set temperature is seen in the preheating step and should generally be consistent with the temperature of the three zones of the extrusion zone.
5) Step of Cooling
The aforementioned specified temperature is actually determined depending on the field conditions, and for example, when the temperature in the processing plant is low in winter (for example, 20 ℃ or less), the air cooling mode can be directly adopted. And when the ambient temperature is higher (for example, more than 20 ℃), the cooling fan can be started to accelerate the cooling of the linear surface coating. The wire obtained by the two cooling modes has whitish surface, low crystallinity of PEEK, high hardness and low toughness. Water cooling needs to cool the PEEK rapidly, the PEEK is discharged from a die opening by about 10cm and completely enters water, namely the PEEK is required to be completely entered water before being completely solidified. The cooling water is required to be clean and pollution-free, and is supplied to the foremost end continuously through a circulating system, so that cold water is ensured to be contacted at the water inlet of the wire all the time, and the temperature of the wire is reduced to dozens of degrees from a mold outlet in a very short time. The temperature of the cooling water can also be controlled by the heater, thereby controlling the cooling speed of the coating. The PEEK coating obtained by the water cooling mode is transparent, the color of the line surface is the color of the paint layer, the PEEK has high crystallinity, the toughness is higher, and the hardness is lower.
6) Step of taking up wire
The PEEK enameled wire does not need to be coated with a surface lubricant before being taken up. And extruding the excess materials in the hearth after the wire is taken up, and performing shutdown cleaning, recovery and other work. The total thickness of the insulation layer of the reeled PEEK enameled wire is more than 300 mu m, wherein the thickness of the PEEK coating is 80-200 mu m.
Of course, the above is one specific embodiment of the present invention. In practice, the substitution of inertia for a part of known steps, or the fine conventional transformation of a part of temperature range under the condition of the known technical process of the present invention, etc. should be considered as equivalent or similar designs and fall within the protection scope of the present invention.
Claims (6)
1. A processing technology of a PEEK electromagnetic wire is characterized by comprising the following steps:
1) preparation in the early stage
Baking the PEEK particles at the temperature of 100-150 ℃ for more than 8 hours;
2) preheating step
Setting the temperature of each heating zone of the extruder, wherein each heating zone comprises a feeding zone, a preheating zone, an extrusion zone and a head part; the temperature of the feeding area is set to be 100-150 ℃; the temperature of the preheating zone is set to be 600-680 ℃; the extrusion zone is divided into three heating zones and the temperature increases in sequence along the extrusion direction: the temperature of the first zone is 280-300 ℃; the temperature of the second zone is 330-360 ℃; the temperature of the three zones is 360-400 ℃, and the temperature of the head part is consistent with that of the three zones in the extrusion zone; after the heating areas are heated in place and the temperature is kept for 30 minutes, the temperature in the feeding machine is ensured to be not lower than 100 ℃, then the feeding is carried out, and the extrusion operation is started;
3) and a step of paying off
After the die orifice of the extruder discharges materials, observing the trend of the die orifice materials, and adjusting the eccentricity of the core wire;
4) extrusion coating step
The machine head and the die orifice of the extruder are heated in a direct contact way through a heating sheet, and the temperature is measured through a hot spot coupling; stopping heating once the temperature exceeds the set temperature, and starting heating when the temperature is lower than the set temperature so as to keep the temperature within the set temperature interval;
5) step of Cooling
When the environmental temperature is below the specified temperature, directly cooling the PEEK enameled wire by air after the PEEK enameled wire comes out of the die; when the environmental temperature is higher than or equal to the designated temperature, cooling treatment is carried out by adopting an air cooling and/or water cooling mode;
6) a wire take-up step;
in the step 2), the core wire for feeding is prepared by the following steps:
a. step of wire drawing
Enabling a copper rod with the diameter of 2.5mm to enter a wire drawing box through a wire releasing device, drawing for multiple times to reach the specification of a specified product, cleaning and drying residual water stains on a wire surface, and then annealing; during annealing, the temperature of the annealing furnace is 450-550 ℃; the annealing temperature in the furnace is heated by an electric heating tube, and the thermocouple monitors and controls the temperature in real time; protecting the copper rod by using water vapor in the annealing furnace, and cleaning the copper wire again after annealing;
b. step of painting
Coating and baking the copper wire treated in the step a for more than eighteen times until a paint film reaches the specified thickness to form the core wire; and then, the core wire is wound on a spool through a winding device, and a surface lubricant is not used on the surface of the core wire before winding.
2. The processing technology of PEEK magnet wire of claim 1, which is characterized in that: and 2) in the step, the preheating area of the extruder is heated by adopting an electric heating tube, and the thermocouple monitors and controls the temperature in real time.
3. The processing technology of PEEK magnet wire of claim 1, which is characterized in that: and in the step 3), after the eccentricity adjustment of the core wire is finished, the core wire is led out from the pay-off machine and sequentially passes through the front tension pulley, the preheating zone, the machine head, the cooling zone and the rear tension pulley to reach the wire coil of the take-up machine.
4. The processing technology of PEEK magnet wire of claim 1, which is characterized in that: in the step 5), the air cooling mode is as follows: and cooling the PEEK enameled wire by an air cooling machine after the PEEK enameled wire is discharged out of the die orifice of the extruder.
5. The processing technology of PEEK magnet wire of claim 1, which is characterized in that: in the step 5), the water cooling mode is as follows: the PEEK enameled wire is directly immersed in cooling water after being taken out of a die orifice of an extruder by 10 cm; the temperature of the cooling water can be controlled by the heater, so that the temperature reduction speed of the coating is controlled.
6. The processing technology of PEEK magnet wire of claim 1, which is characterized in that: the total thickness of the insulation layer of the PEEK enameled wire obtained by the wire collection in the step 6) is more than 300 microns, wherein the thickness of the PEEK coating is 80-200 microns.
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| CN112667003B (en) * | 2020-12-02 | 2022-04-08 | 格力电工（眉山）有限公司 | Temperature control method and device, storage medium and electronic device |
| CN113012847B (en) * | 2021-02-24 | 2021-11-23 | 佳腾电业（赣州）有限公司 | Insulated wire, preparation method thereof, coil and electronic/electrical equipment |
| CN115547588B (en) * | 2022-09-29 | 2023-12-01 | 科城铜业(英德)有限公司 | Horizontal high-speed enamelling machine painting die and painting process |
| CN116476352B (en) * | 2023-06-21 | 2023-08-22 | 江苏君华特种工程塑料制品有限公司 | Fluorine-containing low dielectric constant polyaryletherketone copolymer and application thereof in cable |
| CN116864218A (en) * | 2023-09-04 | 2023-10-10 | 苏州宇盛电子有限公司 | Preparation process of PEEK insulated electromagnetic wire |
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| CN101958158A (en) * | 2010-10-22 | 2011-01-26 | 株洲时代电气绝缘有限责任公司 | Method for preparing corona-resistant enameled wire and product |
| CN109605610A (en) * | 2018-12-27 | 2019-04-12 | 陕西恒通智能机器有限公司 | A kind of control method of 3D printing silk material Forming Quality |
| CN109801745A (en) * | 2019-01-31 | 2019-05-24 | 苏州巨峰电气绝缘系统股份有限公司 | A kind of new-energy automobile driving motor electromagnetic wire and preparation method thereof |
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| US7163655B2 (en) * | 2002-03-28 | 2007-01-16 | Scimed Life Systems, Inc. | Method and apparatus for extruding polymers employing microwave energy |
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| CN101958158A (en) * | 2010-10-22 | 2011-01-26 | 株洲时代电气绝缘有限责任公司 | Method for preparing corona-resistant enameled wire and product |
| CN109605610A (en) * | 2018-12-27 | 2019-04-12 | 陕西恒通智能机器有限公司 | A kind of control method of 3D printing silk material Forming Quality |
| CN109801745A (en) * | 2019-01-31 | 2019-05-24 | 苏州巨峰电气绝缘系统股份有限公司 | A kind of new-energy automobile driving motor electromagnetic wire and preparation method thereof |
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